Device and method for attachment of insulation

ABSTRACT

A thermal break clip for securing insulation between two construction surfaces, and preventing thermal bridges. In another aspect, a method for securing insulation between two construction surfaces. In yet another aspect, an insulation system is disclosed.

The instant application claims benefit of prior U.S. ProvisionalApplication Ser No. 61/251,791 filed on Oct. 15, 2009.

BACKGROUND

U.S. Patent Application No. 20040128930A1 discloses a heat insulatingwall structure in which a cold (thermal) bridge is prevented by reducingheat conduction to a metal framework and the rust of the framework andinternal dew condensation can be prevented.

U.S. Pat. Nos. 6,523,324 and 6,698,157 each disclose insulated panelsfor building systems.

U.S. Patent Application No. 20040111997 discloses a foam wall panelsystem with a Z-shaped wall panel connection device. The Z-shape of thewall panel connection device provides cavities on each side which acceptthe angled edges of foam wall panels that fit within the cavities.Adjacent foam cores having angled edges are secured into the cavities onopposite sides of Z-shaped wall panel connection devices to form acontinuous foam wall.

U.S. Pat. No. 5,758,464 discloses a plurality of insulating panels forinstallation between and insulation of the metal furrings of a wallsystem. Preferred panels have a plastic foam core. The vertical sideedges of the panels are provided with kerfs for enclosure of the metalfurrings and reduction of the thermal bridging conventionally caused bythe furrings.

U.S. Patent Application No. 20060185301 discloses a tie clip used tohold a plurality of preformed insulated concrete forms together. The tieclip could be a definite length of nine gauge high carbon hanger wirecomprising a front portion, a rear portion, a front bend, a middle bend,and a rear bend.

SUMMARY

Attachment of insulation to building structures often suffers fromthermal bridges, which conduct hot or cold air through the insulation,and thus, lead to loss of thermal efficiency of the insulation.

In one aspect, there is provided a thermal break clip for securinginsulation between a first construction surface and a secondconstruction surface, the thermal break clip attached to the first andsecond construction surfaces, wherein the thermal break clip isconstructed of non-heat conducting material. A thermal heat clip may beconducted of plastic. Insulation may consist of thermal insulationboards.

In addition, a thermal break clip may have: a first portion; secondportion; and a central portion, wherein the first portion attaches tothe first construction surface, the second portion attaches to thesecond construction surface; the first and second portions are joinedthrough the central portion; and the insulation is positioned betweenthe first and second portions. Furthermore, the second portion may besubstantially parallel to the first portion, and the central portion maybe substantially perpendicular to the first and second portions. Inaddition, the first portion may extend in the same or opposite directionof the second portion relative to the central portion. Or, the firstportion may extend above a plane defined by the central portion; whilehe second portion may extend both above and below the plane. In thelatter case, the insulation is positioned both above and below the planedefined by the central portion. The first portion or the second portionmay be flexibly attached to the central portion. It is possible for thecentral portion to include a plurality of steps, each step substantiallyperpendicular to the first and second portions.

A thermal break clip may be attached to the first construction surfaceor the second construction surface with a perforation means (such as,but not limited to, screws, nails and the like). Or, a thermal breakclip may be attached to the first construction surface or the secondconstruction surface with an adhesive.

In a further aspect, there is provided a thermal break clip for securinginsulation between a first construction surface and a secondconstruction surface, the clip having a first leg; a second leg; and acentral portion; the first leg substantially parallel to the second leg;the central portion substantially perpendicular to the first and secondlegs; the first leg and second leg extending above a plane defined bythe central portion; the first leg attached to the first constructionsurface; the second leg attached to the second construction surface; theinsulation positioned between the first and second legs, wherein theclip is constructed substantially of non-heat conducting material. Theinsulation may consist of thermal insulation boards.

In yet another aspect, there is provided a thermal break clip forsecuring insulation between a first construction surface and a secondconstruction surface, the clip having a first leg; a second leg; and acentral portion; the first leg substantially parallel to the second leg;the central portion substantially perpendicular to the first and secondlegs; the first leg extending above a plane defined by the centralportion; the second leg extending above and below the plane; the centralportion having one or more steps, each step substantially perpendicularto the first and second legs; the first leg attached to the firstconstruction surface; the second leg attached to the second constructionsurface; the insulation positioned between the first and second legsboth above and below the plane, wherein the clip is constructedsubstantially of non-heat conducting material. The insulation mayconsist of thermal insulation boards.

In yet a further aspect, there is provided a method of securinginsulation between a first construction surface and a secondconstruction surface, the method comprising: a) attachment of aplurality of base thermal break clips to the first construction surface,each base thermal break clip having an opening to receive theinsulation; b) positioning a first portion of the insulation into asubset of the plurality of base thermal clips; c) positioning of aplurality of intermediate base clips onto the first set of insulation,each of the intermediate thermal break clips having a first and secondopening for receiving insulation, and each intermediate thermal breakclip being attached to the first construction surface; d)positioning ofa second portion of insulation onto the second openings of theintermediate thermal break clips; e) repetition of steps c and d untilthe first construction surface is substantially covered by theinsulation; and attachment of the second construction surface to theplurality of base and intermediate thermal break clips; wherein the basethermal-break clips and intermediate thermal-break clips are constructedof non-heat conducting material. Examples of a first constructioninclude, but are not limited to, a concrete wall; a metal deck; adrywall board; and vertical strapping attached to wood siding. Examplesof a second construction surface include, but are not limited to, woodstudding, a drywall board and a fibre board.

Alternatively, a second construction surface may be brick cladding, withan air gap present between the thermal break clips and the brickcladding.

In yet another aspect, there is provided an insulation systemcomprising: a plurality of base thermal-break clips, a plurality ofintermediate thermal-break clips; a plurality of insulation boards; afirst construction surface and a second construction surface, the baseand intermediate thermal-break clips being constructed of non-heatconducting material, wherein: the insulation boards are paired andship-lapped; the intermediate thermal-break clips connect adjacent pairsof ship-lapped insulation; the paired insulation boards are positionedinto each of the plurality of base thermal-break clips; the intermediateand base thermal-break clips are attached to the first constructionsurface, thereby securing the plurality of insulation boards to thefirst construction surface; and the construction surface is attached tothe intermediate and base thermal-break clips.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 illustrates a perspective view of a first embodiment.

FIG. 2 illustrates a perspective view of a second embodiment.

FIG. 3 illustrates a sectional view of a first application of a thermalbreak clip.

FIG. 4 illustrates a sectional view of a second application of a thermalbreak clip.

FIG. 5 illustrates a sectional view of a third application of a thermalbreak clip.

FIG. 6 illustrates a sectional view of a fourth application of a thermalbreak clip.

DESCRIPTION OF EMBODIMENTS

Referring to FIG. 1, a first embodiment of a thermal clip (10) is shownwith a first (15) and second (20) leg joined through a central portion(25). The first leg (10) has an aperture (30) along its length, forreception of a screw (not shown), nail (not shown), or similarattachment means. The first leg (15) is attached to a first constructionsurface (not shown).

The legs (15, 20) can have equal or unequal height. In the embodimentillustrated in FIG. 1, the height (35) of the second leg (20) is lessthan the height (40) of the first leg (15). This allows for use of atool (for example, but not limited to, a screw gun, hammer, etc) forsecuring the attachment means (not shown) through the aperture (30). Assuch, the height (35) of the second leg lies below the aperture (30) toallow for use of an application tool (not shown).

In addition, the second leg may also have an aperture, for attachment toa second construction surface. It is also understood that each leg ofthe thermal clip can include one or more apertures.

Alternatively, a thermal clip of the instant application can be attachedusing means that do not require an aperture. An example of means is, butnot limited to, an adhesive. In a case where an adhesive is used tosecure a leg to a construction surface, there is no aperture in such legof the thermal clip.

The length (45) of the central portion (25) is at least equal to thewidth of insulation (not shown) used. The width (50) of the thermal clipis not limited to any particular range. As an example, where insulationboards are used, the width (50) of the thermal clip (10) is at leastequal to the total thickness of the insulation boards used.

The second leg can be flexibly attached to the central portion, so thatthe second leg can be folded out (in a direction away from the firstleg), to allow for insulation to be installed within the clip. Thesecond leg can then be folded back to its original position.

Alternatively, the central portion (25) may be staggered, rather thanplanar, to accommodate a staggered arrangement of insulation. As anexample, the insulation can consist of a plurality of insulation boardsthat are ship-lapped.

The insulation is positioned in the opening defined by the two legs (15,20) and the central portion (25).

Referring to FIG. 2, a second embodiment of a thermal clip (60) is shownwith a first (65), second (70) and third (75) legs joined through acentral portion (80). The first leg (60) has an aperture (85) along itslength, for reception of a screw (not shown), nail (not shown), orsimilar attachment means. The first leg (65) is attached to a firstconstruction surface (not shown). In this embodiment, insulation ispositioned in both of the openings; i.e. the thermal break clip abutsbetween two pieces of insulation. One opening is defined by the legs(65, 70) and the central portion (80). The other opening is defined bythe leg (75) and central portion (80).

The first and second legs (65, 70) can have equal or unequal height. Inthe embodiment illustrated in FIG. 2, the height (90) of the second leg(70) is less than the height (95) of the first leg (65). This allows foruse of a tool (for example, but not limited to, a screw gun, hammer,etc) for securing the attachment means (not shown) through the aperture(85). As such the height (90) of the second leg lies below the aperture(80) to allow for use of an application tool (not shown).

The third leg (75) is generally aligned with the second leg (70), andextends below the central portion (80). The third leg can be used tosecure or hold insulation from below. In addition, the third and secondlegs can be combined into one continuous leg, extending both above andbelow the central portion (80).

In addition, the second and third legs may each have one or moreapertures, for attachment to a second construction surface. It is alsounderstood that each leg of the thermal clip can include one or moreapertures, as needed.

Alternatively, a thermal clip of the instant application can be attachedusing means that do not require an aperture therein, such as, but notlimited to, an adhesive. In such case, where an adhesive is used tosecure a leg to a construction surface, there is no aperture in such legof the thermal clip.

Another embodiment of a thermal clip of the instant application (notshown) is a variation of the embodiment shown in FIG. 1. The second leg,rather than being on the same side as the first leg relative to thecentral portion, is on the opposite side relative to the centralportion. This type of arrangement is also known in the art as a buttjoint.

In FIG. 2 central portion (80) is shown with a step-type geometry, foruse with insulation, such as insulation boards that are staggered (orship-lapped). The embodiment shown in FIG. 2 is for use with twoinsulation boards, and therefore, the central portion (80) has twosteps, one for each insulation board (not shown). The width of each step(97, 98) is at least equal to the thickness of each insulation board.The height (99) of the step is at least equal to the offset distance ofthe ship-lapped boards. While a step-type geometry is shown in FIG. 2,the central potion can also have a planar geometry (as in FIG. 1), forboard insulation that is stacked aligned, rather than staggered (orship-lapped).

The central portion can be designed to hold a plurality of insulationboards.

The width (100) of the thermal clip is not limited to any particularrange.

The thermal clip (60) illustrated in FIG. 2 is made of material thatdoes not conduct heat, such as, but not limited to, plastic, recycledplastic, propylene, and the like.

A method of securing insulation between two construction surfaces is asfollows:

-   -   1) One or more insulation boards are secured to an edge of the        first wall using a plurality of thermal break clips with the        general shape as shown in FIG. 1 (with or without apertures).        These thermal break clips are attached to the wall surface, and,        optionally to any adjacent structural surface (e.g. a base or        floor, or adjacent wall).    -   2) Insulation boards are then positioned into the openings of        the attached thermal clips. Further boards are attached to an        adjacent set of insulation boards using a plurality of thermal        clips with the general shape as shown in FIG. 2 (with or without        apertures). These thermal clips may be referred to as        intermediate thermal break clips. The intermediate thermal break        clips are attached to the wall surface. Installation of the        insulation boards continues until the wall is covered with        insulation.    -   3) A second construction surface is then applied and secured to        the insulation/thermal break structure, so that insulation is        now between the wall and the construction surface.

FIGS. 3 to 6 provide examples of using a thermal break clip to secureinsulation in a number of settings.

FIG. 3 illustrates a concrete wall application of a thermal break clip(125), for securing insulation (110) between a concrete wall (115) anddrywall (105). The insulation (110) is ship-lapped, and consists of twoinsulation boards. The thermal break clip (125) is secured to thedrywall (105) with a drywall screw (120), and secured to the concretewall (115) with a screw (130).

FIG. 4 illustrates a brick wall application of a thermal break clip(150), for securing insulation (145) between exterior brick cladding(165) and wood studding (140). The insulation (145) is ship-lapped, andconsists of two insulation boards. The thermal break clip (150) issecured to the wood studding (140) with a first screw (170), and securedto the brick cladding (165) with a galvanized brick tie (160). There isa layer of space (155) between the secured insulation (145) and theexterior brick cladding (165). The thermal break clip (150) is furthersecured to the insulation (145) through the perforation attachment means(175).

FIG. 5 illustrates a roof application of a thermal break clip (200), forsecuring insulation (190) between a metal roof deck (210) and a fibreboard (185). The insulation (190) is ship-lapped, and consists of twoinsulation boards. The thermal break clip (200) is secured to the fibreboard (185) with a drywall screw (195), and secured to the roof deck(210) with two self-tapping screws (205). A weatherproof membrane (180)is placed adjacent the fibre board (185).

FIG. 6 illustrates a wood siding application of a thermal break clip(265), for securing insulation (260) between wood studding (255) andvertical strapping (270) which is adjacent to wood siding (275). Theinsulation (260) is ship-lapped, and consists of two insulation boards.The thermal break clip (265) is secured to the wood studding (255) witha first screw (280), and secured to the strapping (270) with a secondscrew (285).

While specific embodiments have been described in detail in theforegoing detailed description and illustrated in the accompanyingdrawings, those with ordinary skill in the art will appreciate thatvarious modifications and alternatives to those details could bedeveloped in light of the overall teachings of the disclosure.Accordingly, the particular arrangements disclosed are meant to beillustrative only and not limiting as to the scope of the invention,which is to be given the full breadth of the appended claims and any andall equivalents thereof.

1. A thermal break clip for securing insulation between a firstconstruction surface and a second construction surface, the thermalbreak clip attached to the first and second construction surfaces,wherein the thermal break clip is constructed of non-heat conductingmaterial.
 2. The thermal break clip of claim 1 having: a first portion;second portion; and a central portion, wherein the first portionattaches to the first construction surface, the second portion attachesto the second construction surface; the first and second portions arejoined through the central portion; and the insulation is positionedbetween the first and second portions.
 3. The thermal break clip ofclaim 2, wherein the second portion is substantially parallel to thefirst portion, and the central portion is substantially perpendicular tothe first and second portions.
 4. The thermal break clip of claim 3,wherein the first portion and the second portion each extend in the samedirection relative to the central portion.
 5. The thermal break clip ofclaim 3, wherein the first portion and the second portion extend in theopposite direction relative to the central portion.
 6. The thermal breakclip of claim 3, wherein the first portion extends above a plane definedby the central portion; the second portion extends both above and belowthe plane; and the insulation is positioned both above and below theplane.
 7. The thermal break clip of claim 1, wherein the first portionor the second portion are flexibly attached to the central portion. 8.The thermal break clip of claim 1, wherein the thermal break clip isattached to the first construction surface or the second constructionsurface with a perforation means.
 9. The thermal break clip of claim 1,wherein the clip is attached to the first construction surface or thesecond construction surface with an adhesive.
 10. The thermal break clipof claim 3, wherein the central portion includes a plurality of steps,each step substantially perpendicular to the first and second portions.11. The thermal break clip of claim 1, wherein the non-heat conductingmaterial is plastic.
 12. The thermal break clip of claim 1, wherein theinsulation consists of thermal insulation boards.
 13. A thermal breakclip for securing insulation between a first construction surface and asecond construction surface, the clip having a first leg; a second leg;and a central portion; the first leg substantially parallel to thesecond leg; the central portion substantially perpendicular to the firstand second legs; the first leg and second leg extending above a planedefined by the central portion; the first leg attached to the firstconstruction surface; the second leg attached to the second constructionsurface; the insulation positioned between the first and second legs,wherein the clip is constructed substantially of non-heat conductingmaterial.
 14. The thermal break clip of claim 13, wherein the insulationconsists of thermal insulation boards.
 15. A thermal break clip forsecuring insulation between a first construction surface and a secondconstruction surface, the clip having a first leg; a second leg; and acentral portion; the first leg substantially parallel to the second leg;the central portion substantially perpendicular to the first and secondlegs; the first leg extending above a plane defined by the centralportion; the second leg extending above and below the plane; the centralportion having one or more steps, each step substantially perpendicularto the first and second legs; the first leg attached to the firstconstruction surface; the second leg attached to the second constructionsurface; the insulation positioned between the first and second legsboth above and below the plane, wherein the clip is constructedsubstantially of non-heat conducting material.
 16. The thermal breakclip of claim 15, wherein the insulation consists of thermal insulationboards.
 17. A method of securing insulation between a first constructionsurface and a second construction surface, the method comprising: a)attachment of a plurality of base thermal break clips to the firstconstruction surface, each base thermal break clip having an opening toreceive the insulation; b) positioning a first portion of the insulationinto a subset of the plurality of base thermal clips; c) positioning ofa plurality of intermediate base clips onto the first set of insulation,each of the intermediate thermal break clips having a first and secondopening for receiving insulation, and each intermediate thermal breakclip being attached to the first construction surface; d) positioning ofa second portion of insulation onto the second openings of theintermediate thermal break clips; e) repetition of steps c and d untilthe first construction surface is substantially covered by theinsulation; and f) attachment of the second construction surface to theplurality of base and intermediate thermal break clips; wherein the basethermal-break clips and intermediate thermal-break clips are constructedof non-heat conducting material.
 18. The method of claim 17, wherein thesecond construction surface is wood studding, a drywall board or a fibreboard.
 19. The method of claim 17, wherein the first constructionsurface is a concrete wall; a metal deck; a drywall board; or verticalstrapping attached to wood siding.
 20. The method of claim 17, whereinthe second construction surface is brick cladding; an air gap is presentbetween the thermal break clips and the brick cladding.
 21. Aninsulation system comprising: a plurality of base thermal-break clips, aplurality of intermediate thermal-break clips; a plurality of insulationboards; a first construction surface and a second construction surface,the base and intermediate thermal-break clips being constructed ofnon-heat conducting material, wherein: the insulation boards are pairedand ship-lapped; the intermediate thermal-break clips connect adjacentpairs of ship-lapped insulation; the paired insulation boards arepositioned into each of the plurality of base thermal-break clips; theintermediate and base thermal-break clips are attached to the firstconstruction surface, thereby securing the plurality of insulationboards to the first construction surface; and the construction surfaceis attached to the intermediate and base thermal-break clips.